Method of making a composite commutator segment and winding element of a bar wound armature



May 30, 1933. v APPLE 1,911,340

METHOD OF MAKING A COMPOSITE comwTAToR SEGMENT AND WINDING ELEMENT OF A BAR WOUND ARMA'I'URE Original Filed June 28, 1927 22 25 Q 5 F g.2. 20" I S Z0 23 a 4" 5 Fig.5. 25 Flg.4F1g-5: x 20 7 24 25 2a METHOD or MAKING A coivirosrrn coimo'm'ron. SEGMENT AND Patented May 30, 1933 UNITED STATES PATENT OFFICE? VINCENT G. APPLE, or DAYTON, 01110; nnnixnnr 1. APPLE, EDWARD M. APPLE, LAND GOURLEY DARROCH ExE-cU'roRs or SAID vI'NonNr G. APPLE, DnonAsED or A BANE WOUND ARMA-TURE WINDING- ELEMENT 1 Original application filed June 28, 1927, Serial No. 202,139. Divided. and this application filed March 24, r

' 1930. Serial no. 438,515. r 1

This invention is a division of my copending application Serial Number 202,139, filed June 28th, 1927, and relates to improvements in that type of armature which comprises a 15 core, a bar winding and acommutator, and

the objects of my improvements are, first, to

provide a structure wherein the-commutatoris an integral part of the winding; second, to provide details of construction whereby the stockfrom which the winding bars are made is used with minimum waste; and third, to producean article that is more durable and dependable. and of'better appearance than when made by present methods.

Further objects will be apparent from the detailed description when reference is made to the drawings, wherein i Fig. 1 shows how a length of bar stock may be notched and cut' apart sothateach part comprises a commutator lug and a conductor 7 bar. Fig. 2 is a cross section taken. at 2'2 of Fig. 3 shows how the two. parts shown in Fig. 1 are reassembled. i Fig. 4. is a cross section taken at 4-4 of Fig. 3. r

Fig. 5 is a crosssection-taken at 55 of 3. l 1 i I Fig. 6 is an endview of-Fig. 7. Fig. 7 shows how the notching shown in Fig. 1 may be eliminated by substitutingspot welding. J i: Fig. 8 is a perspective view of oneunit of my winding. v F ig. 9 is another way of assembling the parts shown in Fig. 8. i

Fig. 10 shows an armature. core lamina havinga commontype of core slot particular- 1y suited to my invention.

Fig. 11 shows two of my improved winding units assembled with a core composed of laminae Fig. 10. l v Fig. 12-shows one pair of straight ends brought together to complete the circuit.

Fig. 13 is a view, partly in section, of a completed armature, insulating material having been molded throughand about the winding to hold it in place and to bind the segments togethertocompose a commutator.

' Similar numerals refer to-similar parts throughout the severaliviews. v

V For, clearness in the following description. aconductor bar so locatedrelative to the commutator lugas to occupy a position in the outerlayer of the completed winding may be referred to as an outer conductor bar and. a conductor bar so located as to occupy a position in the inner layer may be referred to as an inner conductor bar.

Fig. 1 shows how a length of commutator bar stock, preferably copper, may bedivided into two parts bycutting in at one'edge, near. one end, crosswise of the bar and substan.-. tially half way through, then lengthwise of the bar to near the other end, then crosswise of the bar and out through the other. edge, the one part comprising a commutator lug 22 and, an inner conductor bar. 23, the other part comprising a commutator lug 24 and an outer conductor bar 25. i I

In Fig. 2 I show a cross section through a length of bar stock suitable for making the parts shown in Fig. 1, and it will be seen that the sides of the bar are inclined toward each other, forming what is commonly called a wedge shaped cross section. Bar stock of this form is readily obtainable, asit is com- 7 mercially produced in varying wedge angles for use in making commutators of the conr ventional type.

, After th length rated as shown in Fig.1 the one part may be turned end for end and the two commutator lugs 22..and 2 1placedside by side leaving the two conductor bars 23, and.25,extend parallel to each other, although not in the same plane, the cross section Fig 1 showing how the lugs 22 and 24: thus form a composite outline suitable for av commutatorsegment and the cross section Fig. 5 showing the relative position of the conductor bars 23 and 25. i

In Figs. 6 and 7 I show another length of bar stock which has been cut apart in thesame manner as that-shown in Fig. 1, but which has not been notched at the ends as at 20 and 20. After the one part has been-turned end for end and laid alongside the other'part, the two commutator lugs 26 and 27. are spot welded together,and the welding bits are allowed of stock has been sepa placed in the other direction and positioned to-occupy the outer half of another core slot.

The conductor bars may be displaced equal amounts from their commutator lugs or they may be displaced the one more than the other, so long as the total spread between a bar 23 and a bar 25 is suflicient to compose a turn of the winding which is usually about one pole pitch.

The lugs 22 and 24 may be brazed, welded or otherwise joined together either before or after the conductor bars are spread apart, or I may depend on the means afterwards em ployed for binding the whole commutator together to hold the pairs of lugs in contact, one with another, to provide electrical connection therebetween. Fig. 9 shows how the bent portions 31 and 32 of the bars 23 and 25 maybe crossed if desired to achieve a result slightly different but equally as effective as that shown in Fig.8. For clearness in description I will hereinafter refer to two commutator lugs that have been assembled as in Figs. 8 or 9 as a commutator segment.

The winding apertures or slots of armature cores vary considerably 1n contour and proportion, a form much employed being shown in Fig. 10 at 33, 33, etc. The sides of these slots are radial, so obviously the sides of the intervening teeth 34, and 34 are also radial. A slot and a tooth as here shown are, circumferentially, about of equal thickness. Winding units made from wedge shaped stock and formed as in Figs. 8 or 9 are particularly adaptable to slots of this type since a composite commutator segment, composed of a lug 22 and a lug 24, is substantially equal, circumferentially, to a slot 33 and a tooth 34 together, which fulfills a condition required in providinga commutator of substantially the same diameter as the outside diameter of the winding.

Fig. 11 shows an armature core 35 of the type having the sides of the slots and the teeth radial, the slots and teeth being, circumferentially, of substantially equalthickness. Assembled in its slots are two of my improved winding units. One unit comprises a commutator lug 22 having an inner conductor bar 23 integrally extending, and a commutator lug-24 having an outer conductor bar 25 integrally extending. r

The other winding unit comprises a commutator lug 22a having an inner conductor insulating material, though such linings 'are' not shown in the drawings. While for clearness only tWO Of my winding units are shown entered in the core, it is obvious that an entire winding may be arranged in cylindrical formation and simultaneously endwise .entered into the slots of a core in similar manner. V

The free ends of the conductor bars 23, 23a, 25 and25a extend through and considerably beyond the core 35, Fig. 11, and in Fig.

12 I show how one pair of these free ends are bent as at 37 and 38 and thus brought together as at 39 to be joined to complete the circuit, the manner in which this single pair is joined being typical of the entire winding. The joints may be maintained by brazing, welding, or otherwise, welding being an ap proved method, and a welded joint is shown at 40 Fig. 13, but while I have here shown and described a method of joining the free ends of my winding units by bending said ends to form pairs as in Fig. 12, it is obvious that the oldermethod of joining these ends with separate end connectors of involute or other form may be employed if so desired. As the method of stacking a complete set of winding units in cylindrical formation pressing them simultaneously into the slots of a core, bending them simultaneously to form pairs, and joining the pairs by welding to complete the circuit, or joining the free ends with separate end. connectors, is already known to the art, no extensive description thereof is herein contained.

After a suliicient number of winding units are assembled to provide conductor bars to fill all of the core slots, and commutator lugs sufiicient to make: the commutator, and after all of the free ends have been bent andjoined like the single pair-shown in Fig. 12, or joined by separate end connectors, and all havebeen welded as at 40, Fig. 13, or otherwise joined, the armature'may be placed in a mold, and a. fluid insulating material poured or pumped into the mold, and hard ened or allowed to harden by heat or otherwise to form a solid insulating mass as at 41, 41, etc. to bind the segments together. to compose acommutator and to enclose and hold the entire winding in place. 7

Having described my invention, I claim- The method of making a winding unit comprising a commutator segment and two conductor bars comprising a single-turn.

of a two layer bar wound armature from a length of bar stock of wedge shaped cross section which consists of cutting in at one edge at a point as near one end as the length of said segment, crosswise of the bar and substantially half way through, thence lengthwise of the bar to a point as near the other end as the length of the segment, thence outwardly through the other edge, thus separating the bar into two parts, turning one of the parts end for end and placing the segment portions alongside with the flat sides together and the thicker edges both extending in the same direction, passing an electric eurrentfrom one to the other of said segment portions until they soften, pressing them together thereby making deep depressions for a commutator binding means and welding them with the same pressure, then spreading the conductor bars apart to parallel spaced apart positions.

In testimony whereof I aifix my signature.

VINCENT G. APPLE. 

